Awning canopy cover and connection system

ABSTRACT

An awning assembly having an awning connection system for coupling an awning canopy to a support structure and providing a cover to the awning canopy when the awning assembly is in a closed position. The awning connection system comprises a unitary film segment having a distal end connected to the awning canopy and a proximal end for securing to the support structure. The unitary film segment further comprises an attached region for coupling the unitary film segment to the awning canopy.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation application claiming priorityunder 35 U.S.C. § 120 to U.S. nonprovisonal application Ser. No.15/840,485 that was filed on Dec. 13, 2017 and published on Apr. 12,2018 under publication number US-2018-0100309 entitled AWNING CANOPYCOVER AND CONNECTION SYSTEM, which was a divisional application claimingpriority under 35 U.S.C. § 121 to U.S. nonprovisonal application Ser.No. 14/704,487 that was filed on May 5, 2015 and issued on Dec. 26, 2017as U.S. Pat. No. 9,850,663 entitled AWNING CANOPY COVER AND CONNECTIONSYSTEM which was a non-provisional application filed under 35 U.S.C. §111 claiming priority under 35 U.S.C. § 119(e) to U.S. ProvisionalPatent Application Ser. No. 61/988,461 filed May 5, 2014 entitled AWNINGCANOPY COVER AND CONNECTION SYSTEM. The above-identified applicationsare incorporated herein by reference in their entireties for allpurposes.

FIELD OF THIS DISCLOSURE

The present disclosure relates to an awning canopy cover and connectionsystem, and more particular, a system that protects and secures anawning to a structure as well provides protection and an overall visualappeal to the awning assembly.

BACKGROUND

An awning is a welcome addition to a house, recreational vehicle, orother dwelling. The awning typically provides increased enjoyment of anoutdoor area surrounding the dwelling. The awning can cast a shaded areathat creates an escape from direct sunlight, thereby providing a spacein which an occupant of the dwelling may relax. The shaded area createdby the awning contributes to the relaxation of the occupant in thatthere is a perceived decrease in temperature and, thus, generallybecomes more comfortable. The awning as well advantageously protectsoccupants underneath from precipitation.

Known awning structures generally consist of a base that is permanentlyaffixed to the dwelling, and a canopy that is removably attached to thebase. The canopy is typically constructed of vinyl, cloth or acombination thereof. Such known awnings are expensive to fabricate inorder to provide protection to the awning in the stored position asfurther discussed in U.S. Pat. No. 5,437,322 to Murray and U.S. Pat. No.7,604,036 to Thompson et al. both assigned to Carefree/Scott FetzerCompany and U.S. Pat. No. 6,279,641 to Malott assigned to WhiteConsolidated Industries, Inc. collective hereinafter “the AwningPatents”. The above Awning Patents are incorporated herein by referencein their entireties for all purposes.

SUMMARY

One aspect of the present disclosure comprises an awning assembly havingan awning connection system for coupling an awning canopy to a supportstructure and providing a cover to the awning canopy when the awningassembly is in a closed position. The awning connection system comprisesa unitary flexible film segment having a distal end connected to theawning canopy and a proximal end for securing to the support structure.The unitary film segment further comprises an attached region forcoupling the unitary film segment to the awning canopy.

Another aspect of the present disclosure comprises a method ofconstructing an awning assembly having an aesthetic awning cover thatachieves a desired aesthetic appearance, the method comprises the stepsof: providing a unitary film along a first portion of an awning screen,the unitary film being a set width substantially matching the width ofthe awning screen and a portion of the length of the awning screen. Theunitary film is integrally formed from a first polishing material and asecond strengthening material. The method further comprises securing theunitary film by a heating process along the set width to an awningcanopy, the awning canopy having a substantially same width as the setwidth of the unitary film and the awning canopy has a length forming theremaining portion of the awning screen, the combination of the unitaryfilm and the awning canopy forming the awning screen. The method alsocomprises securing the awning screen to a roll bar of an awning assemblysuch that when the awning assembly is in a closed position, the unitaryfilm provides an awning cover to the awning assembly.

While another aspect of the present disclosure comprises an awningassembly having an aesthetic awning cover that achieves a desiredaesthetic appearance. The awning assembly comprises an awning screenhaving a prescribed length and width to form a screened area and toprovide shelter in an extended position, the awning screen is attachedto a roll bar and support hardware allowing the awning screen totransition by coiling onto the roll bar as the awning screen moves fromthe extended position to a closed position. The awning screen isconstructed of a first portion formed by a unitary film and a secondportion formed by an awning canopy. The first portion is attached to thesecond portion and the first portion further includes an area less thanthe area forming the second portion. The unitary film comprises a firstpolished material that is bonded to a second strengthening material, thepolished material comprises a gloss level ranging between 30 and 100%.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The foregoing and other features and advantages of the presentdisclosure will become apparent to one skilled in the art to which thepresent disclosure relates upon consideration of the followingdescription of the disclosure with reference to the accompanyingdrawings, wherein like reference numerals, unless otherwise describedrefer to like parts throughout the drawings and in which:

FIG. 1 is a perspective view of an awning assembly in a retracted orclosed position in accordance with one example embodiment of the presentdisclosure;

FIG. 2 is a side elevation view of an awning assembly in a partiallyexpanded or retracted position in accordance with one example embodimentof the present disclosure;

FIG. 3 is a perspective view of an awning assembly in a expanded or openposition in accordance with one example embodiment of the presentdisclosure;

FIG. 4 is a cross-sectional view of an awning assembly having aconnection system constructed in accordance with one example embodimentof the present disclosure;

FIG. 5 is a partial expanded view of the awning assembly of FIG. 4 inaccordance with one example embodiment of the present disclosure;

FIG. 6 is a cross-sectional view of an awning assembly having aconnection system constructed in accordance with another exampleembodiment of the present position;

FIG. 7 is a perspective view of the awning assembly of FIG. 6 in anexpanded position;

FIG. 8 is a magnified view of portion “8” of FIG. 7;

FIG. 9 is a perspective view of the awning assembly of FIGS. 4 and 5 inan expanded position;

FIG. 10 is a magnified view of portion “10” in FIG. 9;

FIG. 11 is a perspective view of the awning assembly in FIGS. 7 and 9 ina retracted position;

FIG. 12 is a film segment formed with a reinforcement substrate inaccordance with one example embodiment of the present disclosure;

FIGS. 13-16 illustrate manufacturing processes for forming variousunitary films in accordance with multiple example embodiments of thepresent disclosure;

FIG. 17A illustrates a manufacturing process for forming a unitary filein accordance with another example embodiment of the present disclosure;

FIG. 17B illustrates a unitary film constructed in accordance withanother example embodiment of the present disclosure; and

FIG. 17C illustrates a unitary film constructed in accordance withanother example embodiment of the present disclosure.

Skilled artisans will appreciate that elements in the figures areillustrated for simplicity and clarity and have not necessarily beendrawn to scale. For example, the dimensions of some of the elements inthe figures may be exaggerated relative to other elements to help toimprove understanding of embodiments of the present disclosure.

The apparatus and method components have been represented whereappropriate by conventional symbols in the drawings, showing only thosespecific details that are pertinent to understanding the embodiments ofthe present disclosure so as not to obscure the disclosure with detailsthat will be readily apparent to those of ordinary skill in the arthaving the benefit of the description herein.

DETAILED DESCRIPTION

Referring now to the figures generally wherein like numbered featuresshown therein refer to like elements having similar characteristics andoperational properties throughout unless otherwise noted. The presentdisclosure relates to an awning canopy cover and connection system, andmore particular, a system that protects and secures an awning to astructure as well provides protection and an overall visual appeal tothe awning assembly.

Now referring to FIGS. 1-11, an awning assembly 20 is illustrated. Theawning assembly 20 includes a connection system 22 that is mounted to avertical support surface 24, which might be for example, the side wallof a recreational vehicle, mobile home, a recreational vehicleslide-out, or more permanent building structure. The awning assembly 20includes a flexible awning canopy 26 having an inner or proximal edge 28secured to the flexible connection system 22 in a manner to be describedin more detail hereafter and an outer edge 30 secured to a roll bar 32,which can be motor, manually, or spring driven by one or more motors 34,gears, or springs that are operatively connected to and supported by asupport system 36 in the form of a pair of scissors-type arms 38.

In the example embodiment of FIG. 1, the motors 34 are hidden orenclosed to be protected from the elements in respective housings orcovers 35. In the illustrated example embodiment, the covers 35 are madefrom plastic or metal and may include a coated material 39 such asglossy paint or similar protective coatings as applied by a secondarymanufacturing process.

The support system 36 disclosed is of the type shown in more detail inU.S. Pat. No. 6,971,433, which is of common ownership with the presentapplication and the disclosure of which is hereby incorporated byreference. Suffice it to say the support system includes thescissors-type arms 38 mounted on a vertical track 40 on the supportsurface 24. The support system 36 is shown extended in FIG. 3 with theawning assembly 20 in the extended position and fully retracted in FIG.1 wherein it will be appreciated the support system is verticallydisposed and in close adjacent relationship with the support surface 24.

As will be appreciated, and as possibly best illustrated in FIG. 2, asthe motors 34 are driven in one or the other direction (see arrows inFIG. 2), the awning canopy 26 is rolled onto or unrolled from the rollbar 32 causing the awning to retract or extend, respectively incooperation with gas springs 42 associated with each support arm 38. Ofcourse, when the roll bar 32 is rotated as shown in FIG. 2 in a firstdirection A to retract the awning 20 by wrapping the awning canopy 26about the roll bar, the support arms 38 are forced to retract againstthe bias of the gas springs until in the fully retracted first positionof FIG. 1.

To open the awning assembly 20, the roll bar 32 is rotated as shown inFIG. 2 in a second direction B to extend the awning by unwrapping theawning canopy 26 from the roll bar. The support arms 38 are assisted bythe bias of the gas springs until fully extended to the second positionof FIG. 3.

It should be appreciated by those of ordinary skill in the art that theawning assembly 20 in another example embodiment has support arms 38that retract up and/or rotate inwards as indicated by arrows C in FIG. 1by a fixture assembly 44 illustrated in FIGS. 4-6. The fixture assembly44 is fixedly attached to the support surface 24. Moreover, the supportarms 38 and fixture assembly 44 from which they are rotatably attachedin the illustrated example embodiment of FIG. 5 are positioned closer tothe awning assembly 20 support rail 46 relative to the locations shownin the illustrated example embodiment of FIGS. 1-3.

In the illustrated example embodiments of FIGS. 4-11, the support arms38 comprise a plurality of rotatable tubes 48 as would be appreciated bythose of ordinary skill in the art. The rotatable tubes 48 expandoutward to support the outer edge 30 of the canopy 26, similar to theintent of the scissor arms illustrated in FIGS. 1-3.

The awning support rail 46 comprises a tubular support channel 50 forholding an intermediate member 52 having semi-annular tubular first andsecond members 54 and 56, respectively spaced by linear portion 58.First, semi-annular tubular member 54 includes a smaller outer diameterthan the inner diameter of the tubular support channel 50, whichincludes a slot opening along the channel for receiving and retainingthe first semi-annular member 54.

The connection system 22 comprises a flexible or pliable film segment 60of unitary construction for connecting the canopy 26 to the verticalsupport surface 24 via the awning support rail 46 and intermediatemember 52. Because of the film segment's construction, the segment 60can advantageously match, mimic, or contrast the appearance of thehardware of the awning assembly 20 when the awning assembly is in aclosed position acting as an aesthetic cover 63 while still protect theawning canopy 26 without the need and cost of a conventional hard-casehousing. Stated another way, the upper surface 70 comprises a glosslevel that closely resembles painted and plastic components on theawning assembly 20. In one example embodiment, the film segment 60 isrotated about a roll bar 32 multiple times without any reduction in anupper surface 70 gloss level maintaining a gloss unit of measuregenerally between 30 and 100%, and more specifically 90%+/−5% for blackfilms 39B and 80%+/−5% for white and silver (metallic) films.

In one example embodiment, the film segment 60 is a flexible unitarymember comprising a proximal end 62, a distal end 64 spaced opposite theproximal end, first and second sides, 66, 68, respectively, and an uppersurface 70 opposite a lower surface 72. The film segment 60 isapproximately twenty-five percent (10%) of the part of protectivecovering for providing shelter and shade as the screen of the awningwhile the awning canopy 26 makes up the remaining ninety percent (90%),as illustrated in FIGS. 3, 5, and 7-10. In one example embodiment, theflexible film segment 60 is substantially the same width as the awningcanopy 26 and their collective lengths making up the awning screen (seeFIG. 7) of the awning assembly 20.

It should be appreciated that alternative example embodiments the filmsegment 60 could be longer or shorter, making up more or less of theprotective canopy. For example, awning assemblies 20 constructed forslideouts and small windows may have a film segment 60 that is betweenten (10%) and thirty (30%) percent of the total awning length.

The unitary film segment 60 in one example embodiment is a homogeneousfilm, such as polyvinylchloride (“PVC”). While in another exampleembodiment, the unitary film segment 60 is a co-extruded film bondedtogether with a combination of PVC making the upper aesthetic portion 60a of the upper surface 70 and a scrim material 60B (see FIGS. 14-16)providing reinforcement or strength to the unitary film 60. The scrimmaterial 60B is a reinforcement fiber that can be woven into for examplea grid or diamond-shaped pattern. Various embodiments are shown in FIGS.13-16 for manufacturing the unitary film 60.

In yet another example embodiment, the unitary film segment 60 istri-extruded film bonded together with a combination of PVC making theupper aesthetic portion 60 a of the upper surface 70, a scrim material60B, providing reinforcement or strength to the unitary film 60, and PVCforming a lower portion 60 c, as illustrated in FIG. 14. The lowerportion 60 c is the same PVC material as the upper portion 60 a, exceptthinner in thickness. In one example embodiment the upper aestheticportion 60 a is thick enough to prevent the scrim from bleeding throughthe PVC. In another example embodiment, the thickness of upper PVC 60 ais 0.030″ of one inch and lower PVC 60 c is 0.010″ of one inch,providing a stackup of the unitary film 60 with scrim beingapproximately 0.035″ to 0.050″ of one inch, as illustrated by dimensiond_(a) in FIG. 14.

In the illustrated example embodiment, the film segment 60 is a unitaryhomogenous polymeric material, such as but not limited to, athermoplastic material, such as polyvinyl chloride film, polyester, andpolyethylene capable of receiving the coating material or film 39B. Onesuitable example of a polyester film is a product sold under thetrademark Mylar® by the DuPont Corporation. The unitary film segment 60in one example embodiment is extruded as a single uniform polymericmaterial, incapable of separation without destruction and includes aconstruction free of fibers, woven strands, or any combination thereof.

Illustrated in FIG. 12 is an alternative example embodiment wherein theunitary polymeric film segment 60 is laminated to a reinforcementsubstrate 61 to enhance the strength of the film segment forming acomposite cover 63, while allowing it to maintain its upper surface 70properties capable of retaining surface coatings 39B, as discussed belowin more detail. In one example embodiment, the reinforcement substrate61 is a woven or fabric material. In another example embodiment, thereinforcement substrate 61 can either be attached to the canopy 10 in asimilar fashion as the film segment 60 (as further described below) orremain unattached to the canopy, while the film includes such attachmentat its distal end 64.

The film segment 60 forms an attached region 74 substantially along itsentire distal end 64 to the entire proximal edge 28 of the canopy 26from the first side 66 to the second side 68. The attached region 74 inthe illustrated example embodiment is formed by welding the entireattached region of the canopy 26 to the to the film segment 60. Inalternative example embodiments, the attached region 74 secures thecanopy 26 to the film segment 60 by co-extruding both the canopy withthe film segment, hot melt forming, sewing, adhesive bonding (such asglue), or any combination thereof.

Under testing conditions, the welding of the film segment 60 when madefrom polyvinyl chloride film along the attached region 74 will hold willcause failure to the canopy material 26 before yielding occurs in theattached region. That is, the film segment 60 and the attached region74, whether by welding, adhesive bond, sewing, or any combinationthereof is stronger than the canopy material 26.

In one example embodiment, testing occurred and the film 60, andattached region withstood over forty (40) pounds per linear inch beforefailure occurred at the canopy 26, while no failure existed at theattached region 74 or in the film 60. Such testing occurred with acanopy 26 made from polyvinyl chloride fabric comprising woven threads.The relatively uniform construction of the film segment 60 over thewoven polyvinyl canvas provides advantages strength adhering propertiesfrom the welded attached region 74.

In another example embodiment, the reinforcing substrate 61 causes theunitary film 60 to resist stretching and remain stable over the forcesand ambient temperature range the film is subjected to during normaloperating conditions. Thus, the unitary film 60 has even greaterstrength than the canvas material 26 described in the aforementionedexample embodiments.

Referring to the example embodiment of FIGS. 4 and 5, the film segment60 extends between its sides 66, 68 from the attached region 74 at thedistal end 64 to the proximal end 62. The proximal end 62 is then iscoupled to the vertical support surface 24 via awning support rail 46and intermediate member 52. In particular, the film segment 60 includesan annular tubular boss 76 that when installed slides through linearopening 78 into the semi-annular second tubular member 56 of theintermediate member 52. The annular tubular boss 76 is then retainedwithin the semi-annular second tubular member 56, because the outerdiameter of the boss is greater than the distance in the linear opening78.

Referring to the example embodiment of FIG. 6, the film segment 60extends between its sides 66, 68 from the attached region 74 at thedistal end 64 to the proximal end 62. The proximal end 62 is then iscoupled to the vertical support surface 24 via awning support rail 46and intermediate member 52. In particular, the film segment 60 includesa connection region 80 to a keder 82 having an annular tubular boss 84that when installed, slides through linear opening 78 into thesemi-annular second tubular member 56 of the intermediate member 52. Theannular tubular boss 84 is then retained within the semi-annular secondtubular member 56, because the outer diameter of the boss is greaterthan the distance in the linear opening 78. In an alternative exampleembodiment, the proximal end 62 is connected directly to the tubularsupport channel 50, avoiding the need of the intermediate member 52.

The connection region 80 is formed between the film segment 60 and alinear extension 86 of the keder 82 from substantially the first tosecond side 66, 68 of the film segment. In the illustrated exampleembodiment, the connection region 80 is formed by welding the extension86 and proximal end 62 of the film segment 60 together from first andsecond sides 66, 68. In alternative example embodiments, the connectionregion 80 secures the film segment 60 to the linear extension 86 byco-extruding both the keder 82 with the film segment, hot melt forming,sewing, and the like.

In one example embodiment, the keder 82 is of a calendared constructionpolymer or polywrap flat roll stock. For example, one suitable keder 82is a keder manufactured by American Keder under part number 11.0730.7.1.Other suitable examples of keder 82 materials include polyvinyl chlorideand polyester.

As illustrated in FIGS. 1 and 11, when the awning assembly 20 isrolled-up or in the closed position, the only portion of the awningvisible is the film segment 60 between the two housings 35. The unitaryconstruction of the film segment 60 of the present disclosure provides awater tight cover over the canopy 26 portion of the awning when in theclosed or retracted position (see FIG. 1), thus protecting it in asuperior way over aluminum and woven fabrics of traditional awnings.This is further understood by the over 180 degrees of wrinkle-freecoverage provided by the film segment 60 designated by referencedimension “R” illustrated in FIG. 4 about the center “O” of the roll bar32. As well, the unitary construct of the film segment 60 provides atight and compressed diameter “D” over conventional woven fabric wrapawning constructions.

In the illustrated example embodiment of FIG. 4, the diameter D usingthe unitary film segment 60 is capable of compressing the canopy 26 to adiameter D to ¾ ″ to 1″ inch less than a conventional aluminum or metalcover. Thus, greater protection is provided by the film segment 60 tothe canopy 26. As well, the film segment 60 provides from side 66 toside 68 in the closed position a tight wrinkle free appearance notpossible with conventional vinyl fabric covers or wraps.

While yet another advantage of the unitary construction of the filmsegment 60 is the film is capable of mimicking painted or coatedhardware such as the housings 35, as illustrated in FIGS. 1 and 11. Inthe example embodiment, the film 60 provides a gloss appearance level of30-100%, not possible with traditional vinyl or canvas awnings. Statedanother way, conventional vinyl fabric wrap awnings fail to provide suchfinished coating options, because of cracking and other limitationsfound in such materials. While the aluminum covers in conventionalawnings are manufactured at a significantly higher cost in bothmaterials and labor, while remaining bulky and non-uniform inappearance. Moreover, the film segment 60 when acting as a cover in theclosed position of FIGS. 1 and 11 can be extruded with a pigment of adesired color to create a finished coating 39B to match, contrast, ormimic the hardware such as the housings 35 with little additional cost.Alternatively, the film segment 60 because it is not woven or a fabriccan include a finish coating 39B with variations of metal mimickingcoatings, such as anodized finishes, metallic flaking, carbon fiber, orchrome plating, as desired and for example, to match, or complement inan aesthetically pleasing way, the awning assembly 20.

Illustrated in FIGS. 13-16 are manufacturing processes for formingvarious unitary films 60. The unitary films 60 illustrated in themanufacturing processes are bonded to the awning canopy by a heating orextruding operation. In particular, FIG. 13 illustrates a unitary film60 being a homogenous material 60 a that is co-extruded with the awningcanopy 26 through a first pair of pinch rollers followed by a polishingroller (“P”) that adds the gloss polish or coating 39B to the uppersurface 70. The co-extruding process creates the unitary film 60resulting in an integral connection inseparable without destruction. Inone example embodiment, the unitary homogenous material 60 a is PVC andthe awning canopy 26 is vinyl or cloth. In another example embodiment,the polish provided by the polishing roller P provides a gloss level tothe upper surface between 30 and 100%.

FIG. 14 illustrates a unitary film 60 comprising a first material 60 a,a second or middle material 60 b, and a third material 60 c that iscollectively tri-extruded through a first pair of pinch rollers followedby a polishing roller (“P”) that adds the gloss polish or coating 39B tothe upper surface 70 of the first material 6 a. The tri-extrudingprocess creates the unitary film 60, resulting in an integral connectioninseparable between the materials without destruction. In one exampleembodiment, the first material 60 a and third material 60 c is PVC andthe second or middle material 60 b is a scrim fabric. The unitary film60 is then further heat bonded or tri-extruded to connect with theawning canopy 26. In the illustrated example embodiment, the polishprovided by the polishing roller P provides a gloss level to the uppersurface between 30 and 100%. The third material 60 c helps secure thescrim 60 b to the first material 60 a, the scrim 60 b providing strengthto the unitary film 60.

FIG. 15 illustrates a unitary film 60 comprising a first material 60 aand a second material 60 b that is collectively co-extruded through afirst pair of pinch rollers followed by a polishing roller (“P”) thatadds the gloss polish or coating 39B to the upper surface 70 of thefirst material 60 a. The co-extruding process creates the unitary film60, resulting in an integral connection inseparable between thematerials without destruction. In one example embodiment, the firstmaterial 60 a is PVC and the second material 60 b is a scrim fabric. Theunitary film 60 is then further heat bonded or extruded to connect withthe awning canopy 26. In the illustrated example embodiment, the polishprovided by the polishing roller P provides a gloss level to the uppersurface between 30 and 100%.

FIG. 16 illustrates a unitary film 60 comprising a first material 60 aand a second material 60 b that is collectively co-extruded through apair of pinch rollers in which the upper pinch roller is a polishingroller (“P”) that adds the gloss polish or coating 39B to the uppersurface 70 of the first material 60 a. The co-extruding process createsthe unitary film 60, resulting in an integral connection inseparablebetween the materials without destruction. In one example embodiment,the first material 60 a is PVC and the second material 60 b is a scrimfabric. The unitary film 60 is then further heat bonded or extruded toconnect with the awning canopy 26. In the illustrated exampleembodiment, the polish provided by the polishing roller P provides agloss level to the upper surface between 30 and 100%.

In the foregoing specification, specific embodiments have beendescribed. However, one of ordinary skill in the art appreciates thatvarious modifications and changes can be made without departing from thescope of the disclosure as set forth in the claims below. Accordingly,the specification and figures are to be regarded in an illustrativerather than a restrictive sense, and all such modifications are intendedto be included within the scope of present teachings.

FIG. 17A similar to FIG. 14 illustrates a unitary film 60 comprising afirst material 60 a, a second or middle material 60 b, and a thirdmaterial 60 c that is collectively tri-extruded through a pair of pinchrollers. The tri-extruding process creates the unitary film 60,resulting in an integral connection inseparable between the materialswithout destruction. In FIG. 17A, the first material 60 a and thirdmaterial 60 c is PVC and the second or middle material 60 b is a scrimfabric. The unitary film 60 is then further heat bonded or tri-extrudedto connect with the awning canopy 26 at the attachment region 74. In theillustrated example embodiment the attachment region is approximatelyone-inch in length. The third material 60 c helps secure the scrim 60 bto the first material 60 a, the scrim 60 b providing strength to theunitary film 60.

Once the tri-extruded portion of the unitary film 60 is formed in FIG.17A, it is then taken for completion of the remaining portion of theunitary film occurs by a laminating process illustrated in FIG. 17B inwhich a fourth material 60 d of a thin layer (approximately 0.005″) ofpolyethylene terephthalate (PET) a metal mimicking coating 39B, such asanodized finishes, metallic flaking, carbon fiber, or chrome plating tomatch, or complement in an aesthetically pleasing way, the awningassembly 20 is added along with a fifth layer of material 60 e of clearor tinted PVC for scratch, weather, and UV protection that also allowswelding to fabric or canopy 26.

In an alternative example embodiment, the unitary film 60 comprises fourlayers co-extruded as illustrated in FIG. 17C. In FIG. 17 C, the fourthlayer 60 d is a layer of PVC that is a metal mimicking coating 39B, suchas anodized finishes, metallic flaking, carbon fiber, or chrome platingto match, or complement in an aesthetically pleasing way, the awningassembly 20. The fourth layer 60 d of PVC in addition to providing thedesired look also provides protection and adhesive capabilities forwelding to the canopy material 26.

The benefits, advantages, solutions to problems, and any element(s) thatmay cause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeatures or elements of any or all the claims. The disclosure is definedsolely by the appended claims including any amendments made during thependency of this application and all equivalents of those claims asissued.

Moreover in this document, relational terms such as first and second,top and bottom, and the like may be used solely to distinguish oneentity or action from another entity or action without necessarilyrequiring or implying any actual such relationship or order between suchentities or actions. The terms “comprises,” “comprising,” “has”,“having,” “includes”, “including,” “contains”, “containing” or any othervariation thereof, are intended to cover a non-exclusive inclusion, suchthat a process, method, article, or apparatus that comprises, has,includes, contains a list of elements does not include only thoseelements but may include other elements not expressly listed or inherentto such process, method, article, or apparatus. An element proceeded by“comprises . . . a”, “has . . . a”, “includes . . . a”, “contains . . .a” does not, without more constraints, preclude the existence ofadditional identical elements in the process, method, article, orapparatus that comprises, has, includes, contains the element. The terms“a” and “an” are defined as one or more unless explicitly statedotherwise herein. The terms “substantially”, “essentially”,“approximately”, “about” or any other version thereof, are defined asbeing close to as understood by one of ordinary skill in the art, and inone non-limiting embodiment the term is defined to be within 10%, inanother embodiment within 5%, in another embodiment within 1% and inanother embodiment within 0.5%. The term “coupled” as used herein isdefined as connected, although not necessarily directly and notnecessarily mechanically. A device or structure that is “configured” ina certain way is configured in at least that way, but may also beconfigured in ways that are not listed.

The Abstract of the Disclosure is provided to allow the reader toquickly ascertain the nature of the technical disclosure. It issubmitted with the understanding that it will not be used to interpretor limit the scope or meaning of the claims. In addition, in theforegoing Detailed Description, it can be seen that various features aregrouped together in various embodiments for the purpose of streamliningthe disclosure. This method of disclosure is not to be interpreted asreflecting an intention that the claimed embodiments require morefeatures than are expressly recited in each claim. Rather, as thefollowing claims reflect, inventive subject matter lies in less than allfeatures of a single disclosed embodiment. Thus the following claims arehereby incorporated into the Detailed Description, with each claimstanding on its own as a separately claimed subject matter.

We claim:
 1. An awning assembly comprising: an awning canopy having adistal end and a proximal end, the distal end for securing to a supportstructure; and a unitary flexible film segment having a distal enddirectly connected to said proximal end of the awning canopy via asingle connection location between a bottom side of the awning canopyand a top side of the unitary flexible film segment, wherein the unitaryflexible film segment is extruded to connect to the awning canopy; theunitary flexible film segment further comprises an attached region forcoupling said unitary flexible film segment to said awning canopy at thesingle connection location.
 2. The assembly of claim 1, wherein theunitary flexible film segment comprises a color and contrast thatsubstantially matches end caps attached to a roll bar supporting saidawning canopy.
 3. The assembly of claim 1, wherein the unitary flexiblefilm segment is incapable of separation without destruction.
 4. Theassembly of claim 1, wherein the distal end of the unitary flexible filmsegment is attached to the canopy via a single connection locationbetween the awning canopy and the unitary flexible film segment.
 5. Theassembly of claim 1 wherein said awning canopy further comprises anannular tubular boss at said proximal end for securing the awning canopyto the support structure during use.
 6. The assembly of claim 1 whereinsaid unitary flexible film segment is a homogenous uniform material. 7.The assembly of claim 1 wherein said unitary flexible film segment is ahomogenous uniform material that includes an upper surface that isexposed when the awning assembly is in a closed position and covers saidawning canopy, the upper surface construction includes at least one of afinished coating and a polished coating.
 8. The assembly of claim 1,wherein the distal end of the unitary flexible film segment is attacheddirectly to the awning canopy via a single connection location betweenthe awning canopy and the unitary flexible film segment.
 9. A method ofconstructing an awning canopy, the method comprising the steps of:providing a unitary film that is incapable of separation withoutdestruction along a first portion of an awning canopy, the unitary filmbeing a set width substantially matching the width of said awningcanopy, the unitary film being integrally formed from a first polishingmaterial and a second strengthening material; and securing said unitaryfilm by co-extruding the awning canopy and the unitary film along saidset width such that a single side of the unitary film is directlycoupled to a single side of the awning canopy, the awning canopy havinga length forming the remaining portion of an awning screen, thecombination of said unitary film and said awning canopy forming theawning screen, the co-extruding comprising forming a top portion of theunitary film with the first polished material that is bonded to thesecond strengthening material.
 10. The method of claim 9 said polishedmaterial comprising a gloss level ranging between 30 and 100%.
 11. Themethod of claim 9 further comprising forming an annular tubular boss tocomprise a second end opposite the first portion for securing the awningscreen to a support structure during use.
 12. The method of claim 9wherein said first polished material comprises a material suitable forpainting or dying.
 13. The method of claim 9 comprising connecting thefirst portion of the unitary film directly to said awning canopy via asingle connection location between a single side of the awning canopyand a single side of the unitary film.
 14. The method of claim 9 whereinintegrally forming said first polishing material with said secondmaterial further comprises the step of co-extruding said first polishedmaterial with said second material.
 15. The method of claim 9 whereinthe step of securing said unitary film comprises utilizing a heatingprocess along said set width of the awning canopy.
 16. The method ofclaim 9 further comprising providing a third material to the unitaryfilm such that said second material is positioned between said firstpolished material and the third material.
 17. An awning assembly kitcomprising: an awning canopy; a roll bar for coupling to the awningcanopy at a first end of said awning canopy; first and second arms thatare used to support the roll bar; and a unitary flexible film segmentthat is incapable of separation without destruction, the unitaryflexible film segment forming part of said awning canopy and comprising:a distal end that is directly connected to a single side of the awningcanopy; and a co-extruded bond formed with said distal end and saidsingle side of said awning canopy.
 18. The awning assembly kit of claim17, further comprising an annular tubular boss coupled to the awningcanopy at a proximal end of said unitary flexible film for securing theawning canopy to the support structure during use.
 19. The awningassembly kit of claim 17, further comprising an attached region having asingle connection location between the awning canopy and the unitaryflexible film segment.
 20. The awning assembly kit of claim 17, furthercomprising an attached region having a connection location between asingle side of the awning canopy and a single side of the unitaryflexible film segment.